In my Industrial Training in B.H.E.L., Haridwar I go through all sections in Turbine Manufacturing. First management team told me about the history of industry, Area, Capacity, Machines installed & Facilities in the Industry.
After that they told about the Steam Turbine its types , parts like Blades, Casing, Rotor etc. Then they told full explanation of constructional features and procedure along with equipment used. Before telling about the machines used in Manufacturing of Blade, they told about the safety precautions, Step by Step arrangement of machines in the block with a well defined proper format. They also told the material of blade for a particular desire, types of Blades, Operations performed on Blades, their New Blade Shop less with Advance Technology like CNC Shaping Machine.
1. NOIDA INTERNATIONAL UNIVERSITY
GREATER NOIDA
DEPARTMENT OF MECHANICALENGINEERING
INDUSTRIAL TRAINING PRESENTATION
ON
Bharat Heavy Electricals
Limited, Haridwar
(Uttarakhand)
Submitted To :
Ms.Nidhi Sindhu (Asst.Prof)
Submitted By :
Md Shahnwaz Anwer
Mohammad Nadeem Khan
Chandra Pratap Shastri
Naveen Baghel
2. TABLE OF CONTENTS
INTRODUCTION OF B.H.E.L
OVERVIEW OF THE ENTERPRISE
OCCUPATIONAL HEALTH AND SAFETY POLICY
STEAM TURBINES
TYPES OF STEAM TURBINE
MANUFACTURING PROCESS
BLOCK-3 LAYOUT
BLADE SHOP
TYPES OF BLADE
BLADES MANUFACTURING
ACHIEVED DURING THE TRAINING
CONCLUSION
REFERENCES
3. INTRODUCTION OF BHEL
Bharat Heavy Electricals Limited (B.H.E.L.) is the largest engineering and
manufacturing enterprise in India.
Established in 1960s under the Indo-Soviet Agreements of 1959 and 1960 in
the area of Scientific, Technical and Industrial Cooperation.
BHEL has its setup spread all over India namely New Delhi, Gurgaon,
Haridwar, Rudrapur, Jhansi, Bhopal, Hyderabad, Jagdishpur , Tiruchirapalli,
Bangalore and many more.
Over 65% of power generated in India comes from BHEL-supplied
equipment. Overall it has installed power equipment for over 90,000 MW.
BHEL has already attained ISO 9000 certification for quality management, and
ISO14001 certification for environment management.
It is one of India's nine largest Public Sector Undertakings or PSUs, known as
the “NAVRATNAS” or “The Nine Jewels”.
4. OVERVIEW OF BHEL
BHEL was established in 1964.
BHEL is one of the only 7 PSUs of India clubbed underthe esteemed
'Maharatna' status. (1st February2013).
BHEL is engaged in the design, engineering, manufacture, construction,
testing, commissioning and servicing of a wide range of products and
services for the core sectors of the economy, viz. Power, Transmission,
Industry,Transportation (Railway), Oil & Gas and defence.
BHEL has 15 manufacturing divisions, two repair units, four regional offices,
eight service centers and 15 regionalcenters.
9. Steam Turbine
A turbine is a device that converts chemical energy into mechanical energy,
specifically when a rotor of multiple blades or vanes is driven by the
movement of a fluid or gas.
In the case of a steam turbine, the pressure and flow of newly condensed
steam rapidly turns the rotor.
This movement is possible because the water to steam conversion results in a
rapidly expanding gas. As the turbine’s rotor turns, the rotating shaft can work
to accomplish numerous applications, often electricity generation.
11. IMPLUSE TURBINE
The principle of the impulse steam turbine consists of a casing
containing stationary steam nozzles and a rotor with moving or rotating
buckets. The steam passes through the stationary nozzles and is directed
at high velocity against rotor buckets causing the rotor to rotate at high
speed.
The following events take place in the nozzles :
1. The steam pressure decreases.
2. The enthalpy of the steam decreases.
3. The steam velocity increases.
4. The volume of the steam increases.
12. REACTION TURBINE
A reaction turbine has rows of fixed blades alternating with rows of moving
blades.
The steam expands first in the stationary or fixed blades where it gains some
velocity as it drops in pressure.
It then enters the moving blades where its direction of flow is changed thus
producing an impulse force on the moving blades.
In addition, however, the steam upon passing through the moving blades
again expands and further drops in pressure giving a reaction force to the
blades.
This sequence is repeated as the steam passes through additional rows of fixed
and moving blades.
13. HIGH PRESSURE TURBINE
High pressure and temperature fluid at the inlet of the turbine, exit as
lower pressure and temperature fluid.
Specification of HP Turbine
(500MW):
Main Steam Temp- 537˚C
Main steam pressure- 170kg/cm2
Reheat steam temp- 537˚C
Length of Rotor- 4.61m
Height- 2.15m
Weight- 86400kg
14. INTERMEDIATE PRESSURE TURBINE
Intermediate pressure turbine having more pressure then L.P turbine
and less than the high pressure turbine(H.P) . Its blade is larger than
high pressure turbine.
Specification of IP Turbine (500MW):
Main Steam Temp- 537˚C
Main steam pressure- 41kg/cm2
Length of Rotor- 4.425m
Height- 4.80m
15. LOW PRESSURE TURBINE
LP turbine is designed to be a dual flow turbine. Steam enters the centre
of the turbine from the crossover pipe and flows across the reaction
blading in two opposite directions. This configuration reduces axial
thrust on the turbine and allows for a smaller turbine installation.
Specification of LP Turbine (500MW):
Main steam pressure- 8 kg/cm2
Reheat steam temp-320˚C
Length of Rotor- 8.71m
Height- 10.7m
Weight- 345000kg
16. BLADE OF TURBINES (HP, IP & LP)
H.P. Turbine Blades :
The blades are responsible for extracting energy from the high temperature,
high pressure steam produced by the boiler.
17. H.P. TURBINE BLADES
The blades are
responsible for
extracting energy
from the high
temperature, high
pressure steam
produced by the
boiler.
18. I.P. TURBINE BLADES
The size of blades
of I.P steam turbine
is larger than H.P
steam turbine , but
smaller than L.P
steam turbine.
19. L.P. TURBINE BLADES
LP blade is larger
than HP & IP.
Statistics show that
low pressure (LP)
turbine blades are
generally more
susceptible to
failure than those of
the high pressure
(HP) and
intermediate
pressure (HP).
20. BLADES MANUFACTURING
Operations Performed On Blades:
Inspection
Cutting
Milling
Grinding on both the surface
Machining Of Blades:
Horizontal milling machine
Central lathe machine
CNC machine
Vertical boring machine
22. SINUMERIK CNC LATHE
Swing over
carriage:35
00mm
Centre distance
:9000mm
Weight capacity:120 T
Spindle
power:196KW
External
chucking
range:250-
2000mm
Max spindle rpm:200
CNC system
840D:SINU
MERIK
23. SKODA VERTICAL CNC LATHE
Finishing
machining casings
including guide
blade grooves are
carried out in
vertical position
on this lathe. The
machine is
provided with
840C CNC system
27. ACHIEVED DURING THE TRAINING
Gone through rigorous 4 Weeks training under the guidance of capable
engineers and workers of BHEL Haridwar in Block-3 “TURBINE
MANUFACTURING” headed by Senior Engineer of department Mr.
Bhagwanad Pandit situated in Ranipur, Haridwar,(Uttarakhand).
The training was specified under the Turbine Manufacturing
Department. Working under the department I came to know about the
basic grinding, scaling and machining processes which was shown on
heavy to medium machines. Duty lathes were planted in the same line
where the specified work was undertaken.
The training brought to my knowledge the various machining and
fabrication processes went not only in the manufacturing of blades but
other parts of the turbine.
28. CONCLUSION
BHEL is the largest engineering and manufacturing enterprise in
India .
The company manufactures 235 MW nuclear turbine generator sets
and in future it will 500 MW.
BHEL is a major contributor of equipment and systems to industries.
At the all, till now BHEL is best in supply and manufacturing products.